Predictive Maintenance
Monitor equipment health in real-time, predict failures days or weeks in advance, schedule maintenance during planned downtime, and reduce unplanned downtime by 30–50%. Extend equipment life while reducing capital expenses.
/ Manufacturing & Supply Chain /
for Modern Manufacturing
Manufacturing companies face unprecedented complexity: global supply chains, demanding customers, rising costs, and constant pressure to do more with less. Inception55 gives you the visibility and intelligence to stay ahead.
We unify production, quality, supply chain, and financial data so you can predict issues before they happen, keep lines running, and make confident decisions in real-time.
/ common challenges /
Common
▸Production downtime that forces teams into constant firefighting
▸Supply chain chaos triggered by limited visibility into suppliers and logistics
▸Quality issues and rework caused by disconnected inspection and feedback loops
▸Inventory imbalances that tie up capital or trigger stockouts
▸Disconnected data across ERP, MES, quality, and shop-floor systems
/ how inception55 helps /
How Inception55
Real-Time Production Monitoring
Track OEE automatically, see what’s happening on every line, compare planned vs. actual production instantly, and alert supervisors to bottlenecks before they cascade.
Supply Chain Visibility
Track materials from supplier to production to customer, predict supply issues before they impact production, optimize inventory across locations, and identify alternative suppliers automatically.
Quality Management
Connect quality data from inspection, testing, and customer feedback, identify patterns that predict defects, trace issues back to root causes, and reduce scrap while ensuring compliance.
Demand Planning & Forecasting
Predict demand more accurately using AI, balance inventory levels, adjust production plans automatically, and improve forecast accuracy by 30%+.
/ use cases /
Use
Equipment Health & Predictive Maintenance
Before Inception55
- ▸Equipment failures cause 3–5 days of unplanned downtime monthly
- ▸Maintenance is reactive and expensive
- ▸Lost production costs $50K+ per incident
- ▸No way to prioritize maintenance investments
After Inception55
- ▸IoT sensors connected to a centralized platform
- ▸Machine learning models predict failures 2–4 weeks early
- ▸Maintenance scheduled during planned downtime
Impact
- ▸Unplanned downtime reduced by 45%
- ▸$800K annual savings from avoided downtime
Supply Chain Risk Management
Before Inception55
- ▸Supplier issues discovered only when materials fail to arrive
- ▸No visibility into supplier health or alternative sources
- ▸Production delays trigger customer issues and expedited shipping costs
After Inception55
- ▸Real-time tracking of suppliers, orders, and shipments
- ▸AI alerts on supplier risks like delivery delays or quality issues
- ▸Automated identification of alternative suppliers
Impact
- ▸Lead times reduced by 20%
- ▸Emergency shipping costs down 60%
Production Optimization
Before Inception55
- ▸Production planning based on gut feel and spreadsheets
- ▸Bottlenecks discovered too late
- ▸Overtime costs 15% higher than budget
After Inception55
- ▸Real-time dashboards show production status across all lines
- ▸AI optimizes scheduling based on current conditions
- ▸Bottlenecks identified and resolved proactively
Impact
- ▸Overall throughput increased 18%
- ▸Overtime reduced by 25%
/ systems we connect /
Systems We
▸ERP Systems: SAP, Oracle, Microsoft Dynamics, Infor, Epicor, NetSuite, Sage
▸Manufacturing Execution Systems (MES): Rockwell, Siemens, GE Digital, Wonderware, Aveva
▸Quality Management: SAP QM, ETQ, MasterControl, Arena QMS
▸Supply Chain Platforms: Blue Yonder, Kinaxis, o9 Solutions, Oracle SCM
▸Equipment & IoT: SCADA systems, PLCs, industrial sensors, OPC-UA servers
▸Maintenance: IBM Maximo, SAP PM, Fiix, UpKeep
/ customer success /
Precision Parts Manufacturing
$35M manufacturer of precision metal components for aerospace and automotive industries
Challenges
- ▸CNC machine downtime averaging 12% (industry standard: 5–7%)
- ▸Quality defects costing $400K annually in rework
- ▸No visibility into supply chain until parts arrived
- ▸Month-end reporting took 5 days to compile from 8 systems
Solution
- ▸Implemented Inception55 Foundry and AIP
- ▸Connected IoT sensors for predictive maintenance
- ▸Real-time quality monitoring and defect prediction
- ▸Supply chain visibility with risk alerting
- ▸Unified operational dashboards
Results
- ▸Machine downtime reduced to 5.5%
- ▸Quality defects down 65%
- ▸Supply chain disruptions identified 18 days earlier
- ▸Month-end reporting now takes 2 hours
Metrics
- ▸Total annual savings: $1.4M
- ▸ROI: 380%
"Inception55 gave us capabilities we thought were only available to companies 10x our size. The predictive maintenance alone paid for the entire platform in the first quarter."
Ready to see the command center?
Schedule a working session with our industry team to map your use cases and build a proof of value with your data.